U.S. patent application number 16/127371 was filed with the patent office on 2019-01-03 for de-coiling cone.
The applicant listed for this patent is The ESAB Group, Inc.. Invention is credited to Victor Adolfo GONZ LEZ CORTEZ, Gerard KLAES, Mark D. MORRISON, Rodolfo Francisco REP.
Application Number | 20190002232 16/127371 |
Document ID | / |
Family ID | 63581627 |
Filed Date | 2019-01-03 |
![](/patent/app/20190002232/US20190002232A1-20190103-D00000.png)
![](/patent/app/20190002232/US20190002232A1-20190103-D00001.png)
![](/patent/app/20190002232/US20190002232A1-20190103-D00002.png)
![](/patent/app/20190002232/US20190002232A1-20190103-D00003.png)
![](/patent/app/20190002232/US20190002232A1-20190103-D00004.png)
![](/patent/app/20190002232/US20190002232A1-20190103-D00005.png)
United States Patent
Application |
20190002232 |
Kind Code |
A1 |
MORRISON; Mark D. ; et
al. |
January 3, 2019 |
De-Coiling Cone
Abstract
A system for dispensing weld wire comprises a container
including walls and inside corners, a coil of weld wire within the
container, and a de-coiling cone on the weld wire. The coil
includes inner and outer circumferences, and the de-coiling cone
includes an inner ring smaller than the inner circumference of the
coil, an outer ring larger than the inner circumference and smaller
than the outer circumference of the coil, and a plurality of legs
extending radially outward from the inner ring to positions
adjacent respective inside corners of the container. Each leg
includes a first leg portion connecting the inner and outer rings,
a second leg portion extending radially outwardly from the first
leg portion, and a backwardly bent leg portion adjacent a
corresponding inside corner of the container.
Inventors: |
MORRISON; Mark D.; (Fenton,
MO) ; KLAES; Gerard; (Moab, UT) ; REP; Rodolfo
Francisco; (Hanover, PA) ; GONZ LEZ CORTEZ; Victor
Adolfo; (Greer, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The ESAB Group, Inc. |
Florence |
SC |
US |
|
|
Family ID: |
63581627 |
Appl. No.: |
16/127371 |
Filed: |
September 11, 2018 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15625185 |
Jun 16, 2017 |
10087036 |
|
|
16127371 |
|
|
|
|
62476185 |
Mar 24, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B23K 9/173 20130101;
B65H 57/18 20130101; B65H 2701/31 20130101; B65H 2701/36 20130101;
B65H 49/08 20130101; B65H 49/02 20130101; B23K 9/1333 20130101 |
International
Class: |
B65H 57/18 20060101
B65H057/18; B65H 49/02 20060101 B65H049/02; B23K 9/133 20060101
B23K009/133 |
Claims
1.-4. (canceled)
5. A system for dispensing weld wire comprising: a container; a
coil of weld wire disposed within the container; and a de-coiling
cone disposed within the container above the coil of weld wire, the
de-coiling cone including an inner ring, an outer ring, and a
plurality of legs; wherein the inner ring is connected with the
outer ring; wherein each of the plurality of legs includes a
horizontal leg portion extending outwardly from the outer ring to a
backwardly bent leg portion; and wherein a tip of the backwardly
bent leg portion is disposed adjacent the horizontal leg portion of
the leg.
6. The system of claim 5, wherein a gap between the tip of the
backwardly bent leg portion and the horizontal leg portion is no
larger than twice a thickness of the weld wire.
7. The system of claim 5, wherein the tip of the backwardly bent
leg portion is in contact with the horizontal leg portion.
8. The system of claim 7, wherein the tip of the backwardly bent
leg portion is attached to the horizontal leg portion.
9. The system of claim 7, wherein the tip of the backwardly bent
leg portion is welded to the horizontal leg portion.
10. The system of claim 5, wherein the backwardly bent leg portion
is disposed above the horizontal leg portion.
11. The system of claim 5, wherein the backwardly bent leg portion
extends inwardly and downwardly towards the horizontal leg
portion.
12. A de-coiling cone for dispensing weld wire from a container,
the de-coiling cone comprising: a first ring; a second ring
disposed below the first ring; and a plurality of legs; wherein the
first ring is connected with the second ring; wherein each of the
plurality of legs includes a horizontal leg portion extending
outwardly from the second ring to a backwardly bent leg portion;
and wherein a tip of the backwardly bent leg portion is disposed
adjacent the horizontal leg portion of the leg.
13. The de-coiling cone of claim 12, wherein a gap between the tip
of the backwardly bent leg portion and the horizontal leg portion
is no larger than twice the thickness of the weld wire.
14. The de-coiling cone of claim 12, wherein the tip of the
backwardly bent leg portion is in contact with the horizontal leg
portion.
15. The de-coiling cone of claim 14, wherein the tip of the
backwardly bent leg portion is attached to the horizontal leg
portion.
16. The de-coiling cone of claim 14, wherein the tip of the
backwardly bent leg portion is welded to the horizontal leg
portion.
17. The de-coiling cone of claim 12, wherein the backwardly bent
leg portion is disposed above the horizontal leg portion.
18. The de-coiling cone of claim 12, wherein the backwardly bent
leg portion extends inwardly and downwardly towards the horizontal
leg portion.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 62/476,185, filed on Mar. 24, 2017, the
disclosure of which is incorporated by reference herein in its
entirety.
TECHNICAL FIELD
[0002] The present disclosure relates generally to containers for
dispensing weld wire and, more particularly, to a de-coiling cone
for such containers.
BACKGROUND
[0003] In many high production welding environments, weld wire is
delivered to the point of use in a container, such as a drum. The
drum contains a coil of wire long enough to support high production
welding operations for an extended period of time.
[0004] A de-coiling cone may be used to help feed wire out of the
drum. A typical de-coiling cone includes three concentric rings--an
inner ring through which the wire is fed, an outer ring adjacent
the walls of the drum, and an intermediate ring disposed between
the inner and outer rings. The rings are arranged at different
heights and connected by legs or spokes that extend radially
outward and downwardly from the inner ring to the outer ring to
define a cone-like profile. The de-coiling cone rests on top of a
cardboard ring, which rests on the coil of welding wire inside the
drum. The welding wire is consumed as the welding feed system pulls
the wire out of the drum through the inner ring of the de-coiling
cone. The de-coiling cone and cardboard ring ride on top of the
wire, dropping lower into the drum as the wire is consumed.
[0005] Customers expect to continuously feed the wire into their
weld system until the drum is empty. However, tangles occasionally
occur inside the drums. In some applications, particularly those
with larger diameter wire, or with stiffer wire alloys, the wire
tends to tangle due to twist induced in the wire by the customer
feeding system. One of the most common types of tangles observed in
the field occurs when the weld wire moves up above the de-coiling
cone, between the de-coiling cone and the inner liner of the drum,
while the end user is welding. When that happens, the wire
eventually gets caught on the de-coiling cone, causing feeding to
stop, and operator intervention is required.
SUMMARY OF THE INVENTION
[0006] An aspect of the present invention comprises a system for
dispensing weld wire. The system comprises a container including a
plurality of walls defining a plurality of inside corners, a coil
of weld wire disposed within the container, and a de-coiling cone
disposed on top of the coil of weld wire. The coil of weld wire
includes an outer circumference adjacent the plurality of walls and
an inner circumference defining a central opening The de-coiling
cone includes an inner ring having a first diameter smaller than
the inner circumference of the coil of weld wire, an outer ring
having a second diameter larger than the first diameter and smaller
than the outer circumference of the coil of weld wire, and a
plurality of legs extending radially outward from the inner ring to
positions adjacent the inside corners of the container and
connecting the inner and outer rings. Each of the plurality of legs
includes a first leg portion connecting the inner ring to the outer
ring, a second leg portion extending radially outwardly from the
first leg portion, and a backwardly bent leg portion adjacent a
corresponding inside corner of the container. In an example
embodiment, each leg may include a third leg portion that extends
vertically upward from the horizontal first leg portion, and the
backwardly bent leg portion may extend radially inwardly and
downwardly from the third leg portion.
[0007] Another aspect of the present invention comprises a
de-coiling cone for dispensing wire from a container. The
de-coiling cone comprises an inner ring having a first diameter, an
outer ring having a second diameter larger than the first diameter,
and a plurality of legs extending radially outward from the inner
ring and connecting the inner and outer rings. Each of the
plurality of legs includes a first leg portion connecting the inner
ring to the outer ring, a second leg portion extending radially
outwardly from the first leg portion, and a backwardly bent leg
portion. In an example embodiment, each leg may include a third leg
portion that extends vertically upward from the horizontal first
leg portion, and the backwardly bent leg portion may extend
radially inwardly and downwardly from the third leg portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is an exploded perspective view of an exemplary
system for dispensing weld wire from a container according to an
embodiment of the present invention.
[0009] FIG. 2 is a perspective view of the embodiment of FIG. 1,
with the container partially cut-away to show details of the
de-coiling cone and the coil of weld wire.
[0010] FIG. 3 is a perspective view of a de-coiling cone for use in
dispensing weld wire from a container according to an embodiment of
the present invention.
[0011] FIG. 4 is a top view of a de-coiling cone as shown in FIG.
3.
[0012] FIG. 5 is a side view of a de-coiling cone as shown in FIG.
3.
[0013] FIG. 6 is a cross-sectional view of a portion of a
de-coiling cone taken through line 6-6 in FIG. 4.
DESCRIPTION OF EXAMPLE EMBODIMENTS
[0014] The present inventive concept is best described through
certain embodiments thereof, which are described in detail herein
with reference to the accompanying drawings, wherein like reference
numerals refer to like features throughout. It is to be understood
that the term invention, when used herein, is intended to connote
the inventive concept underlying the embodiments described below
and not merely the embodiments themselves. It is to be understood
further that the general inventive concept is not limited to the
illustrative embodiments described below and the following
descriptions should be read in such light.
[0015] Additionally, the word exemplary is used herein to mean
"serving as an example, instance or illustration." Any embodiment
of construction, process, design, technique, etc., designated
herein as exemplary is not necessarily to be construed as preferred
or advantageous over other such embodiments.
[0016] A system 10 for dispensing continuous running weld wire from
a container according an embodiment of the present invention is
shown in FIGS. 1 and 2. The system 10 includes a container 12, a
coil of weld wire 14 disposed within the container, and a
de-coiling cone 16. The system may also include a lid 18. The
container 12 includes a plurality of walls 20a-h defining a
plurality of inside corners 22a-h. In an exemplary embodiment, the
container is a drum with an octagonal cross-section defined by
eight vertical walls and having eight inside corners. The coil of
weld wire 14 has a generally cylindrical configuration and includes
an outer circumference 24 adjacent the plurality of walls and an
inner circumference 26 defining a central opening. The coil of weld
wire 14 also has a generally flat top 28. The de-coiling cone 16
rests directly on top of the coil of weld wire within the
container, and weld wire 29 from the coil may be fed through the
de-coiling cone as shown.
[0017] As best seen in FIGS. 3-6, the de-coiling cone 16 includes
an inner ring 30, an outer ring 32, and a plurality of legs 34a-h.
In an exemplary embodiment, the number of legs is equal to the
number of inside corners of the container. For example, a
de-coiling cone for an octagonal container may have eight legs as
shown. Inner ring 30 is disposed in a first plane P.sub.1, and
outer ring 32 is disposed in a second plane P.sub.2 below the first
plane. Planes P.sub.1 and P.sub.2 are preferably parallel as shown.
Inner ring 30 has a diameter D.sub.1, and outer ring 32 has a
second diameter D.sub.2 larger than D.sub.1. The inner and outer
rings 30 and 32 are preferably concentric. The legs 34a-h extend
radially outwardly from angularly spaced locations around the inner
ring 30 to connect with the outer ring 32 and extend radially
outwardly from the outer ring.
[0018] As best seen in FIG. 6, each of the plurality of legs
includes an angled first portion 36 connecting the inner ring 30 to
the outer ring 32, a horizontal (or flat) second portion 38
extending radially outwardly from the outer ring, a third portion
40 extending upwardly from the horizontal portion, and a backwardly
bent fourth portion 42 extending radially inwardly and downwardly
from the horizontal part. While the third portion is shown
extending vertically upward from the second portion, it will be
appreciated that the third portion may be curved to provide a
smoother and/or rounded transition between the horizontal leg
portion and the backwardly bent portion.
[0019] The backwardly bent portion extends the effective length of
each leg, thereby increasing the overall weight of the de-coiling
cone, which allows the de-coiling cone to lay flat on the coil of
weld wire during de-coiling operations without the need for an
intermediate member (such as a cardboard ring) between the
de-coiling cone and the coil of weld wire. The backwardly bent
portion also helps eliminate sharp edges that can catch on the
container and prevent the de-coiling cone from moving properly and
maintaining contact with the coil as the weld wire is consumed. A
tip of the backwardly bent portion 42 may touch the horizontal
portion 38, or it may be spaced slightly above the horizontal
portion with a small gap G therebetween as shown, to discourage
wire from becoming tangled in the legs. The gap G is preferably no
more than twice the thickness of the weld wire in the container
(e.g., no more than about 0.125 inch for typical MIG wire). In
another embodiment, the tip of the backwardly bent portion 42 may
be welded or otherwise attached to the horizontal portion 38 to
eliminate the possibility of any gap.
[0020] While the backwardly bent leg portion is shown having a
first horizontal part that extends radially inwardly from the
vertical leg portion and a second angled part that extends radially
inwardly and downwardly from the first horizontal part, it will be
appreciated that the backwardly bent leg portion may have other
configurations, including but not limited to a single angled part
that extends radially inwardly and downwardly from the vertical leg
portion, a continuously curved configuration (e.g., a spiral
configuration), a configuration with multiple bends (e.g., a
zig-zag configuration), a rectangular configuration, etc. In an
example embodiment, a length of the backwardly bent leg portion may
be at least as long as the horizontal portion, thereby
significantly increasing the weight of the de-coiling cone.
[0021] Respective bottom surfaces of the horizontal leg portions 38
are preferably in the same plane. In an exemplary embodiment, a
bottom surface of the outer ring 32 is also in the same plane as
the bottom surfaces of the horizontal leg portions 38.
[0022] As best seen in FIGS. 2 and 4, the diameter D.sub.2 of the
outer ring 32 may be smaller than the inner circumference 26 of the
coil of weld wire 14, and the plurality of legs 34a-h may extend
radially outward from the outer ring to positions adjacent
corresponding inside corners of the container 12 such that only the
legs are disposed directly above the coil of weld wire. Configuring
the outer ring of the de-coiling cone to be slightly smaller than
the inner circumference of the coil of weld wire (e.g., about 0.5
inch smaller) encourages the weld wire to slide smoothly across
this ring as the wire is pulled up and out of the container. Also,
if the walls of the container are deformed, they are less likely to
contact the outer ring and impede the de-coiling cone from moving
downwardly in the container as the wire is consumed. In an
exemplary embodiment, suitable for most weld wire, the inner ring
may have a diameter of about 5.75 inches and the outer ring may
have a diameter of about 12.38 inches, with a vertical spacing of
about 2 inches between the inner and outer rings so that the angle
.theta. between the angled leg portion 36 and the horizontal leg
portion 38 of each leg (see FIG. 6) allows for smooth feeding. In
an exemplary embodiment, the angle .theta. between the angled and
horizontal portions of each leg is about 152.degree. (.+-.a few
degrees). In an exemplary embodiment, the number of legs is equal
to the number of inside corners of the container and the length of
each leg is configured to position the vertical portion 40 at the
end of the leg adjacent a respective inside corner of the container
to limit lateral movement of the de-coiling cone in the container
and discourage wire from rising above the de-coiling cone in the
corners. In an example embodiment, the ends of the legs (e.g.,
vertical portions 40) are immediately adjacent respective inside
corners of the container but are slightly spaced therefrom by a gap
small enough to prevent the de-coiling cone from rotating more than
a few degrees while discouraging contact with the corner that may
result in binding. In an example embodiment, the horizontal portion
of each leg has a length that is 15%-25% of the diameter of the
outer ring, and preferably about 20% of the diameter of the outer
ring.
[0023] In an exemplary embodiment, components of the de-coiling
cone of the present invention may be formed of steel wire and
welded together. For example, galvanized wire with a round
cross-section may be used. While other materials and manufacturing
methods may be used, it is important that the weight of the
de-coiling cone be sufficient to avoid being lifted off the coil of
weld wire or otherwise displaced during de-coiling operations. We
have found that a cone weight of about 1.6-2.0 pounds is sufficient
for most weld wire, although the de-coiling cone may be configured
to be lighter or heavier if desired.
[0024] The descriptions above are intended to illustrate possible
implementations of the present inventive concept and are not
restrictive. Many variations, modifications and alternatives will
become apparent to the skilled artisan upon review of this
disclosure. For example, while a container with eight walls is
shown, it will be appreciated that the container may include fewer
or more than eight walls. The container may also be disposed with
an outer container of different cross-sectional shape, such as a
square cross-section. While it is preferred that the de-coiling
cone have the same number of legs as the number of inside corners
of the container, the cone may have fewer or more legs than the
number of inside corners. Additionally, while the de-coiling cone
is configured to rest directly on the coil of weld wire without the
need for any intermediate member (such as a cardboard ring)
therebetween, a cardboard ring may be placed between the de-coiling
cone and the coil of weld wire. Also, while a de-coiling cone with
only two concentric rings is preferred to minimize manufacturing
costs and inhibit contact between the walls of the container and
the de-coiling cone, a third concentric ring of larger diameter may
be placed above the legs to add weight to the de-coiling cone,
particularly if the diameter of the third ring is such that there
is sufficient room between the ring and the walls of the container
to limit the possibility of contact therebetween in the event of
wall deformation. Thus, it will be appreciated that components
equivalent to those shown and described may be substituted
therefor, elements and methods individually described may be
combined, and elements described as discrete may be distributed
across many components. The scope of the invention should therefore
be determined not with reference to the description above, but with
reference to the appended claims, along with their full range of
equivalents.
* * * * *